Apparatus for molding soap



C; o. PHILLIPS.

APPARATUS FOR `II'IOLDIN SOAP.

APPLICATION FILED JUNE-5. 1920.

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` 0.0. PHILLIPS'.

PPARATus Fon M'OLDING SOAP.

APPLICATION FILED JUNE 5, 1920.

1,391,970. Pandsept. 27,1921.

4 SHEETS-SHEET 2.

C. 0. PHILLIPS.

APPARATUS FOR NIOLDING SOAP.

APPLICATION F1LEnJuNE5.19zo.

1,391,970. -PatentedSept 27, 1921.

M www 0. PHILLIPS. APPARATUS FOR MOLDING SOAP.

APPLICATION FILED JUNE 5, 1920.

M Suva/Wto@ @331g @ff/tomma PM my# WAM UNITED STATES PATE NT oFEicE.

CECIL O. PHILLIPS, OF NEW YORK, N. lY., ASSIGNOR T0 THE AMERICAN COTTON OIL COMPANY, 0F NEW YORK, N. Y., A CORPORATION OF NEW JERSEY.

APPARATUS Fon MoLDING Soar.

Specification of Letters Patent.

. Application led .Tune 5,1920. Serial No.- 386,912.

To all whom may concern.'

Be it known that I, CECIL O. PHILLIPS, a citizen of the United States, residing at New York, in the' county of New York, State New York, have inventedcertain new and ,useful Improvements` in Apparatus for Molding Soap; andzI do hereby declare the following to be a full, clear, and exact 'de'- scription of the invention, such as will enable others skilled in the art to which it appertains to make and use the same.

This invention relatesto an improved apparatus for the molding and cooling of moltensoap in a rapidand advantageous manner. y

-With theimproved apparatus, the'soap, while still molten, is charged into molds of approximately the shape of the desired cake, and Ipassed through a cold saltvsolution or brine where i it is cooled without being brought into direct contact with the brine' Thesoap cakes thus preliminarilycooled are then discharged from themolds and subjected directly to the action of the cold brine, wherebythe cooling and hardening.

operation is very materially promoted. The soap cakes-thiiscooled are then preferably washed with fresh "waterto free the outer surfaces of the cakes from` brine.

The improved apparatus of the invention comprises a receptacle for the brine used in cooling the soap, and a series of molds cylindrically arranged and rotatable in the brine bath together with means for iilling `thc molds with-molten soap, for protecting the vsoap while passing through the brine fromv direct contact therewith, and means for discharging` the cooled soap from the molds.

Y The improved apparatus of the present invention, incertain of its novel aspects, in.v

clu'des thecombination of a soap molding and cooling device, suchnas thatabove reiferred to, with a brine bath and suitable conveying means forcontinuously subjectingthe molded cakes of. soap to the direct `action of thev brine after they have been subjected to the pr'eliminarymolding and cooling.

The invention includes other` features vof improvement, which will further appear from thev following'vmore detailed ydescription. In a copending application, Serialk No.386,913, executed :concurrently `'herewith, an apparatus for molding soap is described, in vwhich the molds :tor the 'soap' cal manner in the ystuing boxes 5 and is in-turn bearings 6, and supports 7. The shaft 4"' are arranged on a rotating table or support, l whereby the cakes of soap are caused to travel in indirect contact, with cold brine, and subsequently in direct contact with brine sprayed thereon. The present apparatus dif fers `from that of the above mentioned co` pending application, iny that the molds are arranged on a rotating drum, the soap cakes are directly subjected to the action of cold brine, and certain accessory devices are provided for removing the soap from the molds.

The preferred form of apparatus, embodying the invention, is illustrated in aV more or less conventional and diagrammatiaccompanying drawings, but it is intended, and will be understood, that the invention is illustrated by, butis not limited to, the'speciie embodiment ythus illustrated and described. In the'accompa'nyingdrawings 'f Figure l is a sectional elevationtakeno of the molding and cooling apparatus`,7cer tain parts being omitted; Fig. 2. is a vertically transverse section taken on the line 2-2 of Fig. l;

ri ht side `of the apparatus of Fig.'1;

ig. 4 i's an enlarged sectional view of the leftside of the apparatus of Fig. l;

Fig. 5 is an enlarged sectional-view, similar to part of Fig. 2, taken on the line 5-5 of Fig. 4;' i

Fig. 6 is a detail view showing the con'- struction of the mold sections;

Fig. 7 is a detail View of one of the ade` justable cam surfaces, taken on 'theline v7 7 of Fig. 3; and Figs. 8 and 9 are a planv and-elevation of part of the apparatus not illustrated in Figs.

`l and 4.

Fig. 3 is an enlarged sectional view ,of the I In the apparatus illustrated in the accom'-I panying drawings, the tank for the cold salt Y Solution or `.brine is indicated at `l and is" suitably supported by the supports 2 and 3 and by the shaft 4 which passes through the supported by carries the spiderl or wheel 8 having the radially arranged outer rim 9 vwhich in' turn supports Vthe transverse the mold sections 1l.

shape of thecake of soap Ito be molded, each' moldhaving. afpiston 13 and piston rod 14 arms 10 vcarrying Each moldv section has three' molds12, of approximately the with a roller 15 at its inner end. The arrangement of the. mold sections and molds is such that they form a cylindrical series of molds rotating upon the shaft 4.

Above the cylindrical series of molds is the soap container 16 having steam jackets 17 for maintaining the soap at the proper temperature and preventing undue cooling thereof. The soap container is supported by the upright supports 18 and has three filling compartments 19 each havinga filling screw 2O therein operated by means of bevel gears 21 and 22. The shaft 23 carrying the gear -22 is in turn operated by the ratchet wheel 24 and a pawl carried by the arm 25. This arm 25 is reciprocated by the operating rod 26, adjustably connected thereto, so that the operation of the ratchet can be controlled by the adjustment of the rod 26 upon the arm 25. I

Power is applied t@ the apparatus through the pulley 27 with which the worm 28 and the beveled pinions 30 and 33 are directly connected through the shaft 27a. The worm 28 drives the worm gear 29 which in turn causes the shaft 4 and the series of cylindrical molds carried thereby to be slowly but continuously rotated. The bevel gear 30 drives the bevel gear 31 which in turn causes the operating arm 32 to rotate and thereby reciprocate the rod 26 as above described. The bevel gear 33 drives the gear 34 attached to the shaft 35 which in turn operates the cams 38 through the bevel gears 36 and 37. Thev pinion 39 on the shaft 35 meshes with a gear 4() on the shaftv 41 which in turn operates fthe shaft 44 through the bevel gears 42 and 43. The shaft 44 carries the arms 45 arranged to act upon the cooled soap cakes to remove them from the pistons.

A series of operating camsV or cam surA faces, adapted to act lupon the rollers 15,

are suitably supported `a short distance from the series of molds. The cams or cam surA faces are arranged in series of three corresponding to the three series of molds, so that the rollers of each series will be similarly and simultaneously acted upon. The cam segment 46 carrying the angle irons 46a is thus supported by a transverse bracket 47 from the plate 48 which in turn is supported by the upright supports 18`and 49. The angle irons 46a of the cam segment 46 provide a Hat surface for the rollers 15. Near its right end this cam segment has an outer surface 52 aswell as an inner surface 51 thus providing a groove 50 for the rollers and insuring that the rollers and the pistons operated thereby are properly positioned. This groove -is inclined inwardly for reasons hereinafter explained. The cam section 53 is pivoted at 54 and adjustably supported at 55 from the adjustable support 56. This cam section likewise provides a double cam groove. The cam section 57 is Vof simiforms the cam surface is pivoted at 66a and adjustable by means of the slots 66 and bolts coperating therewith. The cam surface formed by the member 65 is eccentrically arranged so that the right end thereof is somewhat nearer tothe cylindrical molds than is the left end, for reasons hereinafter explained. The cam section 67 has a centrally arranged outer cam surface 68 and has an adjustable slide support 69 similar to that above described.

Arranged below eachof the three series of molds, to the right of the soap container in Fig. 3, are spray pipes 70 for spraying the under surface of the molds with cold brine and thereby effecting a 'preliminary cooling thereof. Above the molds when in the same position is a cooling jacket 71 having a brine supply pipe 71", and adapted for the i'iow of a cold salt solution or brine therethrough over the inner plate 71a for cooling the outer portion of the soap in the molds. Arranged circumferentially around the series of molds, while immersed in the A slide 76 is arranged to receive the molded and cooled cakes of soap as they are discharged from t-he molds and a spray pipe 77 is arranged for spraying brine upon the slide or upon the cakes as they are discharged. Arranged to the left of the soap container 16 in Fig. 1 is a transversely arranged belt 79 carrying brushes, said belt being supported by the bracket support 81 and driven in-any suitable manner, as by a belt 80. These brushes are arranged to remove any adhering soap from the cylindrical mold sections 11 and the pistons 13, which', as shown, may project somewhat above the surrounding surfaces.

The tank 82 is provided for subjecting.

. troduced into' the soa maniero cakes of soap are discharged on to the'apron or slide 97 and the conveyer 98 and carried thereby to the driver or to the place of storage or further treatment. The conveyer, on its return, is guided by the idlers 94, '95, 88 vand 96, the idlers 95 being adjustable to take up slack-in the conveyor. Spray pipes 99 for brine are arrangedV over the tank 82 and spray pipes 100 for fresh water are arranged over the fresh water tank 89.

ln the' operation of the apparatus, the molten soap from the crutchers and compounded with the usual ingredients, is in container 16, and is maintained therein y the steam jacket at the proper temperature.' The cylindrical .series of'molds isslowly and continually rotated by means 'of thef worm 28 and worm gear 29 and the three series of molds are brought successively beneath the soap container. The pistonsin each mold are kept flush with the urrounding surface of the mold sections, yv the action of thel double cam groove 50, upon thel rollers 157 when .the molds are first introduced beneath the soap container. As the molds'pass beneath the compartments 19, the pistons are drawn downwardly Vby the rollers operating in the double cam groove .ofthe-cam s ection 53 vandsoap is simultaneously forced down 1 into the molds by the action of the screws' 20. AThe intermittent operation of the'screws, and the llowering of the pistons, are so timed that the soapv is forced downwardly into the molds lat the same time that the pistons are drawn downwardly bles or air pockets.

n brinethus' acts through .the v-bandf 72zand` therein. The combined actionres-ults in the filling of the molds with t'he molten soap and. with substantial clusion or-inclu'sion in As the filled molds are rotated Abeyond the soap container, they are subjected .to the cooling" action of thecold brine spray from the pipe andto the cooling action of thecooling jacket 71, the spray acting upon the inner surfaces of the molds and the surface l71a acting directly upon the outer surface of the soap in the molds. The

soap is thus given a preliminary chill be-v foreit isimmersed in the brine in the tank 1. The molds'are then passed down into' thetank r1, but the soap in the molds is protected by the strap 'or band 172 from.

direct Contact with the brine. rllie cold throughthe inner' walls of `the individual molds, Without. however, vcomingi'nto direct Contact withthe soap inthe molds. Thev soap' is then rapidly' cooled and the outer portions of the cakes rapidlysolidified.,`

During the preliminary cooling ofthe soa'pin the molds an appreciable shrinkage takes' place, but this' is compensated for lby the'eccent'ric arrangement of the cam sur- -for the'shrinkage of the cakes.

avoidance of the octlie mold of air bub- The `the edge Yof the soap. container.

face 65, that is, by making the lower right band end of the cam surface, (as shown in Fig. 3),'somewhat closer to the cylindrical molds than the upper left hand end. As, the rollers 1 5 pass over'theeccentrically ar:y ranged cam surface, they are forced out-.. Wardly and in turn force the pistons outwardly a sufficient distance to compensate The` cam section 67 has its cam surfaces concentrically arranged and adjusted to keep the pistons and cakesfof soap vin proper position; The soap cakes' are thus kept in contact with the walls of the molds andwith the band or'strap 72, sothat effective. cooling through the walls of the mold and through thejstrap or band will take place.

After the soap in the molds has become set Aand cooled, the outer surfaces of the cakes are yexposed to the direct action of the cold brine as vthey pass upwardly above Vthe end of the strap 72. rAs the molds come into alinement with the cams 38 these cams act upon the rollers and the pistons to force the cakes ofsoap out ofthe molds, and the cakes Aare then separated from the pistonsl by the arms 45. Theoperation of the cams '8S Vand of the arms 45 is so timed thattlie somewhat beyond the cylindrical surface of-the mold sections, and any adhering soap is thenbrushed from the pistons and from the surface of the mold sections by the belt brush 79. Upon further rotation of the molds the pistonsaredrawn down evenwvith the surrounding surfaces of the mold' sections, by the action of the cam groove 50 upontherollers,'and the pistons .are held in this position when 'the molds. `first pass beneath the soapcontainer.

It will thus .be seen that the position (if the pistons in the molds is controlled by.

the various cam surfaces acting upon thev rollers 15', and that the 'cam surfaces are with or slightly beyond'the cylindrical surface of the Inold` sections. while thecakesof soap' are being separated from the pistons by the arms 45 and while the pistons `are being freed from` adhering soap by the belt brush 79. The pistons .are .then kept flush while the molds are'fbeingl passed beneath4 tons arev thenf drawn inwardly neouslywith the forcing of the soap intov 'adjustable to vary theaction of the pistons. pistons are thus forced outwardly` even .with the surrounding cylindrical surface The p isl simultathe molds by the screws 20, so that the molds are completely filled and the inclusion of air bubbles or pockets prevented. The eccentric arrangement of the cam surface 65 then causes the pistons to move outwardly, as the molds are being rotated, to compensate for the shrinkage of the cakes upon initial cooling, and the cam surface 68 keeps the pistons and cakes Vof soap in position until the molds reach the lowest portion ofl their travel. Upon further rotation of the molds they, are ultimately brought-in alinement with the cams 38 and the cakes forced outwardly and separated from the molds and piston, after which the operation is repeated.

The thickness of the cakes ,of soap can be varied, Without changing the construction of the apparatus, by adjusting the cam surfaces so as to vary the positions of the pis tons in the molds during the operation. A thinner or a thicker cake of soap can thus be produced. It will be understood that the three cam surfaces for the three series of molds can be simultaneously adjusted,'so that the pistons of any three corresponding molds of the different series will be oper- `ated simultaneously and in the same way.

Immediately below the soap container 16 is a receptacle 101 for any soap that may escape around mthe pistons or otherwise.

This soap is collected in the receptacle 101 and thus prevented from dropping into the brine. It can be scraped out of the receptacle, from time to time, as may be necessary. lith proper construction and fitting of the pistons in the molds and with proper' operation of the apparatus, little if any escape into the receptacle should take place.

fter the cakes of soap have been separated from the molds they pass into the tank 82 and are carried therethrough upon the conveyer 83, preferably of foraminous material, such as wire cloth. The arrangement of this conveyer is preferably such that the cakes, in the case of floating soap, are partly or nearly immersed, and the upper surface of the soap is subjected to the cooling action'of the spray from the spray` pipes 99. There the soapis non-floating, it may be completely immersed therein. The soap cakes are thus exposed to the direct cooling action of the brine and are thus further cooled. The length of the tank SQ and the period of time during which the cakes of soap pass through the brine c an be regulated to give the desired cooling action;

After ,the cakes have thus been further cooled they are .preferably washed or sprayed with fresh water to remove the ad- A hering brine. This can be effected by passing the cakes' ofv soap through the tank 89 containing fresh Water and spraying theupper surfaces of the cakes With fresh Water from the pipe 100. This Washing of the cakes with fresh Water is not necessary, but it is desirable for the higher grades of soap to free the surface from brine. A relatively short treatment with fresh Water will usually sufiice. The cakes of soap are then carried by the screen or belt 83 to the conveyer 98 from `which they are carried to a suitable drier or to a place of storage or further treatment. The brine employed can be kept at th proper temperature by any suitable cooling means, for example, by the use of ammonia refrigeration apparatus. Brine may thus be cooled to a temperature of around 5 to 15 F, so that an energetic cooling action will take place. lVith this temperature, it requires but a few minutes to affect the necessary molding and 'cooling of the soap cakes.

'As a result, the apparatus can be operated in a relatively rapid and continuous mane ner,'so that it will have a large capacity.

The preliminary cooling of the soap While in the molds takes place Without exposing the soap to the direct action of the brine, and the cakes of soap are thereafter directly exposed to the cooling action of the brine and thereby further cooled. It will be understood that the apparatus of the present invention can be used for the molding andI cooling of the `soap Without subjectingthe cakes of soap to subsequent direct cooling with brine, as well as in combination with the tank 82 4or equivalent means for subjecting the soap cakes to such direct cooling action, but the capacity of the apparatus is materially increased, and the cooling is ef-l fected in a particularly advantageous manner,by combining the preliminary cooling within the molds with the subsequent cooling by- Adirect contact with the brine.

It will be evident that the molds may be of different sizes and shapes, for example, such that the resulting cake will be of oval, round, square, rectangular or other shape, by properly designing the individual molds and pistons. 1

Inasmuch as certain materials are corroded byi the action of the brine, the apparatus should be constructed of material ,which is not acted upon, or, if constructed paratus should be enameled or otherwise protected from corrosion. The parts of the apparatus which are immersed in the brine may thus be coated with enamel or they may be made of materials which require no protection against corrosion.

Soaps of different character canbemolded and cooled in the apparatus and according to the process of the present invention. The soap may thus be floating soap of high-purity, or it may be laundryor other soap containing other detergent ingredients in admixture with the soap. The soap, prior to molding and cooling, is subjected to the usual preliminary treatments, well understood in the art. The soap, after such preliminary treatments, and while still molten, is brought to the soap container l'at a temperature of `around 150 to 175 F, and

charged into the molds at, approximately the same temperature.

lVhile the apparatus illustrated and de# scribed has three series of molds, it will be understood that the apparatus canbecon.- structed and .operated in a similar manner with the larger or smaller number of series. So, also, the specific construction illustrated and described can be varied without departi g from the spirit and scope of the invention.

1. An apparatus for molding and cooling soap, comprising a series of vidual cakes of soap cylindrically arranged and opening radially outward, means for filling the molds with molten soap, means for moving the molds through a cooling liquid and relatively with respect to the liquid whereby to subject the molds to the action of continuously changing liquid, and means in connection j with the molds for protecting the soap from direct contact with' the liquid. 2. An apparatus for molding and cooling soa-p, comprising a `series of molds for indi- /2 vidual cakes of soap cylindrically arranged and opening radially outward, means for lillying said molds with molten soap, means for rotating said s eries of molds within a reyfceptacle containing cooling liquid and for f'exposing all sides o'f the molten soap to the cooling action of such liquid, andmeans for /ejecting the-cooled soap fromthe molds. 40' 3. An apparatus for molding and cooling l soap, comprising aseriesof cylindrically arranged molds, each mold having a piston and operating rod, adjustable cam surfaces' Aarranged to regulate the positions of the are being lled with molten soap, other cam means for ejecting the cakes of soap from the molds when cooled, and vmeans for 'moving the series vof molds through a cooling liquid and moving relatively to the liquid, whereby to subject the molds to the action of constantly changing liquid.

4. An apparatus` for molding and cooling soap, comprising a tank for a cooling liquid a cylindrically arranged series of molds for individual cakes of soap arranged to rotate in a tank of cooling liquid, and through the liquid the individual molds opening radially outward, means for filling the molds and. means within the tank for protecting the outer surface of the tact with the cooling liquid while immersed therein.

5. An apparatus for molding and cooling soap, comprising. a cylindrically arranged Vcontact with the said around the periphery of molds for indi'- for filling the molds with pistons within the molds 'while the molds,

soap from direct conof. cooling liquid, means for filling the molds and means for protecting the' outer surface of the soap from direct' contact withl the cooling liquid while immersed therein, said means `'comprising a strap or belt held in outer. surface of the soap in themolds.

6. An apparatus for molding and'cooling soap comprisin a tank containing the ooling liquid, a cyndrically arranged series of molds rotatable` `therein, means forl filling the Amolds -with molten soap, and an adjustable band or apron arranged in the tank the series o f molds to protect the soap contained ltherein from direct contact with the cooling liquid.

7. An apparatus for molding and cooling soap comprising a series of molds, means for yfilling the molds with moltenA soap, means for subjecting the .molds to the'action of a cooling liquid and for protecting the` soap from direct Contact therewith, means for discharging the cakesof soap from the moldsL and means for subjecting them to the direct cooling action of the cooling liquid. 8. An apparatus for molding and cooling soap comprising` a series of molds, meansmolten soap, mea-ns for subjecting'the same to the action of a cooling liquid andfor protecting the. soap from direct contact therewith, an, ejector for discharging the soap from the molds and meansfor bringingA the ejector f soap intov direct'contact with the cooling 100 liquid, whereby `the soap is subjected to a preliminary cooling operation in the molds and a subsequent.- cooling action in direct Contact with theV cooling li uid.

9. An apparatiishfor mol ing'and cooling 105 soap comprisingJ a tank for the cooling liquid, a series of molds arranged to be immersed therein, means for lilling the molds with molten soap, mea s for discharging the soap from the molds, a separate receptacle containing cooling liquid and means for passing the soap after removal from the molds through the cooling liquid in'said receptacle.

`10. An apparatus for molding and cooling soap comprising a tank for the cooling liquid, a series ofmolds arranged to be i1nmersed therein, means for filling the molds with molten soap, means for discharging the soap from the molds, a separate receptacle containing cooling liquid, means for passing the soap after removal from the molds through the cooling liquid'in said receptacle, and means for thereafter subjecting the soap to the action of fresh water. x

11. An apparatus for molding and cooling soap comprising a receptacle for cooling liquid, a central shaft supporting a circum` ferential series of molds arranged to rotate in said liquid, each of said molds havin apistol? liberal-1 1 With @Il inwardly extendmg 130 piston rod, means for filling the molds with molten soap, means for protecting the soap in the molds from direct contact with the cooling liquid, a series of cams arranged to act upon the piston rods to assist in thefilling of the molds with the molten soap and to maintain the soap under compression in the mold While cooling, and separate cam means for discharging the soapffrom the molds.

l2. An apparatus for molding and cooling soap comprising a cylindricay arranged series of molds rotatable in a tank of cooling liquid, means for illingthe moldswvith molten soap, each mold having a piston therein with an inwardly extending piston rod, cam surface arranged to act upon the piston rods to subject the soap to' compression While it is being cooled, and a stationary surface around a periphery of the molds against which the soap is forced by said piston. I

13. An apparatus for molding and cooling soap comprising' a cylindrically 4arranged series of molds each having a piston with an inwardly extending piston rod, means for filling the molds with molten soap, means for subjecting the soap in said molds to the action of the cooling liquid, and an eccentrically arranged cam surface adapted to act upon the pistons to force the soap outwardly in the molds While it is being cooled.v

14. An apparatus for molding and cooling soap, comprising a cylindrically arranged series of molds rotatable in the cooling liquid, means for filling the molds with the molten soap, each mold having a piston therein Wit an inwardly extending piston rod, means or acting upon the piston rods to eject the soa'p from the molds, cams arrangedA to keep the pistons even with or somewhat above the outer cylindrical periphery of the molds, and a ybrush arranged `to remove adhering soap from the outer cylindrical mold surface and from the pistons prior to' the subsequent refilling ofthe molds.

l5. An apparatus for molding and cooling soap, comprising a cylindrically arranged series of molds, rotatable in a tank of cooling liquid, said molds being open and exposedv cooling liquidA and for compressing vthe soap to compensate for contraction, means for discharging the soap from the molds, and means for removing any soap adhering to the molds prior to the subsequent molding operation.

In testimony whereof I aix my signature.

CECIL O. PHILLIPS. 

